78 Bronco build, nice but usable - Page 2 - Ford Bronco Forum
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post #21 of 282 (permalink) Old 02-10-2016, 11:34 AM
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post #22 of 282 (permalink) Old 02-10-2016, 11:39 AM Thread Starter
JAN. '17 F.O.T.M.
 
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Quote:
Originally Posted by schwim View Post
Looks fantastic! I'm looking forward to watching this one!
Thanks Brotha

Quote:
Originally Posted by B-man View Post
Oh hell yeah... This is just getting better and better..
Thanks for the compliment

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Originally Posted by trustyrusty View Post
awesome

sweet build so far

looking forward to more pictures

hope my 78 project turns out 1/2 that nice
like the colours
Thanks man, I do have tons of pics

Quote:
Originally Posted by tbrooks View Post
Looking good! Don't get burned out with detail and let the quality go down. Can't wait to see the finished product.

TB
Thanks man, this is why I started with the interior, then I will have to make everything else match the quality.
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post #23 of 282 (permalink) Old 02-10-2016, 11:40 AM Thread Starter
JAN. '17 F.O.T.M.
 
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I found some original seats, and brackets at Driven with a center console. I knew I
wasn't going to use the center console I just figured I would use it to build a new
on, or as a template.









I know they look ruff, but I plan on having them re-upholstered to match everything else.
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post #24 of 282 (permalink) Old 02-10-2016, 12:08 PM Thread Starter
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I don't really plan on using the rear seat all that much there is just me and the wife, so
to make room for a 12" sub in the center console I had to go back with it, knowing I wouldn't
be able to tilt the seat forward to make room in the back.

Here is just starting mock up:




I used 1/4" PVC and 1/2" PVC to make the shapes. I also took note of the arm rests on the doors to
gauge how tall I wanted the center console.




I didn't just want a square type of look so I put some curves in there to match the rest of the BKO




I built the speaker box out of particle board twice (I used a different type the first time and pretty much fell apart)
lesson learned.







starting to come together with the looks and strength I was looking for.





I was able to use a heat gun and bend the PVC over a pipe to get it right where I wanted it. I also got
some cup holders in there (can't do it without those).




I found a hinge, and handle from a local junk yard that would work, and something to latch to at the Depot.
I also through in on each side a cigarette lighter socket (can never have enough power outlets)











after this everything was sent off to Upholstery
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post #25 of 282 (permalink) Old 02-10-2016, 01:07 PM Thread Starter
JAN. '17 F.O.T.M.
 
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There was no room (without a lot of work) to put a double din in and I wanted built
in GPS.
I found a Clarion single bin that had everything that I wanted, but the screen
wouldn't open without some modification to the dash. When the screen would
open it wouldn't open all the way because it would hit the air condition control
knobs.

So to fix this I modified the metal bracket by extending where the radio set about
an 1-1/2" out from where it normally did, also I cut down the knobs on the air control
knobs with a dremel











I also made good use of some of the PVC I had left over from the head liners, and center console to
use to cover the metal pop-out for the radio, and glued them on the cluster cover:





I painted it all up, and put it together:








I installed the amps. The one for the Sub went under the passenger seat:









I mounted the other amp (for the other 4 speakers) under the driver seat, but can't seem to find the photos on it right now.

gotta have good sounding tunes in the BKO
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post #26 of 282 (permalink) Old 02-10-2016, 01:45 PM Thread Starter
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I got everything back from upholstery I think it turned out great:









The rear of the Center console









Cutting out the holes, and mounting the speakers in the rear quarter panels.
this made me very nervous being that I just got them back from being upholstered:

first I cut the whole with a razor blade, then used a drill bit to drill the PVC


















And the rear quarter panels mounted and done:














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post #27 of 282 (permalink) Old 02-10-2016, 01:51 PM
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Really appreciate the interior work. I have not put my interior back in since I mounted up my corbeau front and tahoe rear seats. Love the amp under the flip base and the interior panels are rock solid.

What was the cost to do the interior panels?

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post #28 of 282 (permalink) Old 02-10-2016, 04:07 PM Thread Starter
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Quote:
Originally Posted by deathmobile2 View Post
Really appreciate the interior work. I have not put my interior back in since I mounted up my corbeau front and tahoe rear seats. Love the amp under the flip base and the interior panels are rock solid.

What was the cost to do the interior panels?
I think they were about 50 bucks for a 4X8 sheet
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post #29 of 282 (permalink) Old 02-10-2016, 04:11 PM Thread Starter
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I forgot about these .... I just think they are cool





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post #30 of 282 (permalink) Old 02-10-2016, 04:34 PM Thread Starter
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Here is a few with more put together:
















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post #31 of 282 (permalink) Old 02-10-2016, 04:46 PM
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It's beautiful. I really like your choices with design and the two tone looks great.

1978 Bronco XLT Ranger: 351M with Edelbrock intake, FAST EZ EFI 2.0, FAST dual sync dizzy, FAST E6 ignition box, Wild Horses Hydroboost and Sag pump kit, C6 Trans, Dana 44 front and 9" rear

Jim
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post #32 of 282 (permalink) Old 02-10-2016, 04:49 PM Thread Starter
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Originally Posted by RAMPNT1 View Post
It's beautiful. I really like your choices with design and the two tone looks great.
Thanks brotha, much appreciated !!!!!!
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post #33 of 282 (permalink) Old 02-10-2016, 05:42 PM Thread Starter
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Like I had said before, I had a 77 F150 that I figured I could swap parts to make 1 good truck.

The Motor was a 400 and had been rebuilt with less than 100 miles on it. The problem with it was

it has been sitting 20 plus years and hasn't ran since I parked it.


So my plan was to pull it out, replace gaskets, make it look pretty with paint and valve covers.

here they are next to each other after pushing it out from the side of the house.





I think this is after pulling the motor




The motor pulled out of the BKO and getting ready to clean and paint












sum fresh paint, the color of the interior that I had picked for both interior and exterior (which I later changed my mind)










and now we are ready to start working on the motor
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post #34 of 282 (permalink) Old 02-10-2016, 06:36 PM Thread Starter
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The old 400 out of the BKO. I had actually got it running before pulling it out. The thing had been leaking oil
for a long time (the previous owner had some plumbing under the oil sender that was leaking) and there were large
sponges put on the bell housing to soak it up. I couldn't believe it.
you can also see the other motor in the background





The rebuilt motor before I started working on it:







here it is with new valve covers, plugs, wires, water pump, fuel pump, water and oil sender, clutch, pressure plate, and I'm sure much more than I can remember right now.









and going into the Bronco





My retired neighbor was always over helping out. He must love this kind of thing because he was over a lot, and was a great help.



got it running, but definitely some problems with carb (I hadn't rebuilt it yet) and huge intake leak. so off with the carb, and intake







now it only took me three times to get the intake on. Three gaskets later the rubber kept popping out
after a day or so. Finally I got another neighbor over that is actually a mechanic by trade and knows
about these older motors.

He used a hammer and punch to punch little divets in the cast block (on the ridges)
I guess it mushrooms up and give the rubber gasket something to bite on.

He had me only tighten it to 10 foot pounds, then let it set overnight and finish tightening it the next day.
It worked perfectly.





Well now it's running perfect, just leaking oil like crazy out the rear main seal that I forgot to put in when the motor was out.
needless to say, I had the rear seal but now I have to get another oil pan gasket.... the second one.


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post #35 of 282 (permalink) Old 02-11-2016, 01:13 AM
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Great build so far. I love the interior! It gave me some great ideas for my #2 build.

2- 1978's and 1 Early Bronco. All in various states of dismantlement.
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post #36 of 282 (permalink) Old 02-11-2016, 01:06 PM Thread Starter
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Quote:
Originally Posted by phelman View Post
Great build so far. I love the interior! It gave me some great ideas for my #2 build.
Thanks man , I'm glad you like it. I'm hoping some will get some good ideas from it as I did from so many other posts on here.
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post #37 of 282 (permalink) Old 02-11-2016, 01:31 PM Thread Starter
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Well after getting it running, it did run well but I want this thing like new (or better than new)

so I decided to get a MSD EFI system to match the MSD ignition I already had. So I ordered that

up from Summit racing along with Edelbrock sump kit.

I went this way because the BKO already had a new gas tank, fuel pump and good lines and to do there whole

kit would have been more work. I had read where someone had done the same set up and

was very happy with it.

They worked perfect together, and the MSD computer controls it and everything.


I also got an MSD dizzy so the EFI system could also control the timing as well.

I can't find many pictures of the install that I know I have somewhere but here is a start.




so I sent off some plans to a friend in California for a bracket to mount the Sump and

he made it out of Stainless steel and was perfect.


I used the mounting bolts that mounted the radiator:











Here it is mounted up:





And all hooked up:




I can't say enough good things on the MSD EFI set up. after running a couple of tanks of gas this thing

running wise is flawless cold starts and all.


Now is the start of the bodywork
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post #38 of 282 (permalink) Old 02-11-2016, 01:46 PM
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I'm really enjoying this build. The interior turned out great. Especially the rear panels. Keep the pics coming.
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post #39 of 282 (permalink) Old 02-11-2016, 03:31 PM Thread Starter
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Quote:
Originally Posted by 79BroncoSpringTx View Post
I'm really enjoying this build. The interior turned out great. Especially the rear panels. Keep the pics coming.
Thank you
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post #40 of 282 (permalink) Old 02-11-2016, 03:33 PM Thread Starter
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Well when I bought this BKO I thought it was pretty straight and no rust, but as it

turns out both doors, front fenders, and tailgate were actually pretty bad (under the

bondo and paint).

a lot of bondo (almost an inch in some places) that had covered up holes where someone

tried to pull out dents.

I ended up repairing the doors but took a long time (I am not a body man but have been

in the paint and body industry for 30 years) and the repairs began.



I took the doors, front fenders, and the tailgate off to work on them on a stand

much easier to work on that way.








you can see some of the holes someone had drilled to attempt to pull dents.
(I welded them all before I was done)

here I am actually pulling the dents:









this little guy hung around for a week or so while I worked on the doors. He must have been

someones pet or something, it had a metal tag around one of his feet (or claw)






some of the bondo work











this is one of the doors primed. The Primer I used was a modified epoxy primer.

Usually epoxy type primers are really tough to sand (maybe that was in the older days though)

but this one you could put on bare metal, use as a super heavy filling primer, a mid range primer, or a sealer

all in the same can. Is all you have to do is mix it differently.

It sands real easy although I did it three times (tons of sanding). An experienced body man could have probably done this in

a day or two but took me 2-1/2 weeks.

I taped off the edges and curves so when I was blocking I didnt sand that part. When I was done blocking I pull the tape and

pay special attention when sanding there. On curves and edges it's very easy to sand through and mess it up.








After priming and sanding twice, I primed it one last time and then put a light coat of black over the top called

guide coat.

This guide coat helped me a lot. Being that I'm not a body man I can take 400 grit sand paper and a hand board (keeping it flat)

and sanding the black away. If there are any spots that still have black on it, these are low spots and you will see them

when you put a glossy topcoat or paint over the top of them. I guess you could say guide coat is an insurance policy.






More work on the fenders








Primed







pretty rough tailgate, but only on the surface, not too much body damage though








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